Multi-tunnel electric motor/generator

ABSTRACT

Disclosed are various embodiments for a new and improved electrical motor/generator, specifically a motor/generator comprising: a plurality of coils radially positioned about a coil assembly, a plurality of magnetic tunnels forming a relative rotational path for the coil assembly, wherein the all of plurality of magnets forming each magnetic tunnel have like poles facing inward toward the interior of the magnetic tunnel or facing outward away from the interior of the magnetic tunnel such that each magnetic field of any magnetic tunnel is of an opposite polarity to the magnetic field of an adjacent magnetic tunnel.

RELATED APPLICATIONS

This application is a Continuation of U.S. patent application Ser. No.15/492,529, entitled “An Improved Multi-Tunnel ElectricMotor/Generator,” filed Apr. 20, 2017, which is a Continuation-in-Partof PCT International application serial number PCT/US2016/026776,entitled “An Improved Multi-Tunnel Electric Motor/Generator,” filed onApr. 8, 2016, which claims the benefit of U.S. provisional patentapplication Ser. No. 62/173,349 entitled “Multi-Tunnel ElectricMotor/Generator,” filed on Jun. 9, 2015; U.S. provisional patentapplication Ser. No. 62/167,412 entitled “Multi-Tunnel ElectricMotor/Generator,” filed on May 28, 2015; and U.S. provisional patentapplication Ser. No. 62/144,654 entitled “Multi-Tunnel ElectricMotor/Generator,” filed on Apr. 8, 2015. This application is also aContinuation-in-Part of U.S. patent application Ser. No. 14/866,788,entitled “Brushless Electric Motor/Generator,” filed on Sep. 25, 2015,which claims the benefit of U.S. provisional patent application Ser. No.62/056,389, entitled “DC Electric Motor/Generator with EnhancedPermanent Magnet Flux Densities,” filed on Sep. 26, 2014; U.S.provisional patent application Ser. No. 62/055,615, entitled “DCElectric Motor/Generator with Enhanced Permanent Magnet Flux Densities,”filed on Sep. 25, 2014; and U.S. provisional patent application Ser. No.62/055,612, entitled “DC Electric Motor/Generator with EnhancedPermanent Magnet Flux Densities,” filed on Sep. 25, 2014; and which is aContinuation-in-Part of U.S. patent application Ser. No. 13/848,048,entitled “DC Electric Motor/Generator with Enhanced Permanent MagnetFlux Densities,” filed on Mar. 20, 2013, which claims the benefit ofU.S. provisional patent application Ser. No. 61/613,022, entitled“Electric Motor/Generator,” filed Mar. 20, 2012, of which all of thedisclosures are hereby incorporated by reference for all purposes.

This application is also commonly owned with the following U.S. patentapplications: U.S. patent application Ser. No. 15/413,228, entitled“Brushless Electric Motor/Generator,” filed on Jan. 23, 2017; U.S.patent application Ser. No. 14/866,787, entitled “Brushed ElectricMotor/Generator,” filed on Sep. 25, 2015; U.S. patent application Ser.No. 14/608,232, entitled “Brushless Electric Motor/Generator,” filed onJan. 29, 2015; U.S. patent application Ser. No. 14/490,656, entitled “DCElectric Motor/Generator with Enhanced Permanent Magnetic FluxDensities,” filed on Sep. 18, 2014, the disclosures of which are herebyincorporated by reference for all purposes.

TECHNICAL FIELD

The invention relates in general to a new and improved electricmotor/generator, and in particular to an improved system and method forproducing rotary motion from an electromagnetic motor or generatingelectrical power from a rotary motion input.

BACKGROUND INFORMATION

Electric motors use electrical energy to produce mechanical energy, verytypically through the interaction of magnetic fields andcurrent-carrying conductors. The conversion of electrical energy intomechanical energy by electromagnetic means was first demonstrated by theBritish scientist Michael Faraday in 1821 and later quantified by thework of Hendrik Lorentz.

In a traditional electric motor, a central core of tightly wrappedcurrent carrying material creates magnetic poles (known as the rotor)spins or rotates at high speed between the fixed poles of a magnet(known as the stator) when an electric current is applied. The centralcore is typically coupled to a shaft which will also rotate with therotor. The shaft may then be used to drive gears and wheels in a rotarymachine and/or convert rotational motion into motion in a straight line.

Generators are usually based on the principle of electromagneticinduction, which was discovered by Michael Faraday in 1831. Faradaydiscovered that when an electrical conducting material (such as copper)is moved through a magnetic field (or vice versa), an electric currentwill begin to flow through that material. This electromagnetic effectinduces voltage or electric current into the moving conductors.

Current power generation devices such as rotary alternator/generatorsand linear alternators rely on Faraday's discovery to produce power. Infact, rotary generators are essentially very large quantities of wirespinning around the inside of very large magnets. In this situation, thecoils of wire are called the armature because they are moving withrespect to the stationary magnets (which are called the stators).Typically, the moving component is called the armature and thestationary components are called the stator or stators.

In most conventional motors, both linear and rotating, enough power ofthe proper polarity must be pulsed at the right time to supply anopposing (or attracting) force at each pole segment to produce aparticular torque. In conventional motors at any given instant only aportion of the coil pole pieces is actively supplying torque.

With conventional motors, a pulsed electrical current of sufficientmagnitude must be applied to produce a given torque/horsepower.Horsepower output and efficiency then is a function of design,electrical input power plus losses.

With conventional generators, an electrical current is produced when therotor is rotated. The power generated is a function of flux strength,conductor size, number of pole pieces and speed in RPM. However outputis a sinusoidal output which inherently has losses similar to that ofconventional electric motors.

Specifically, the pulsed time varying magnetic fields produces undesiredeffects and losses, i.e. iron hysteresis losses, counter-EMF, inductivekickback, eddy currents, inrush currents, torque ripple, heat losses,cogging, brush losses, high wear in brushed designs, commutation lossesand magnetic buffeting of permanent magnets. In many instances, complexcontrollers are used in place of mechanical commutation to address someof these effects.

Additionally, in motors or generators, some form of energy drives therotation and/or movement of the rotor. As energy becomes more scarce andexpensive, what is needed are more efficient motors and generators toreduce energy consumption, and hence costs.

SUMMARY

In response to these and other problems, there is presented variousembodiments disclosed in this application, including methods and systemsof increasing flux density by permanent magnet manipulation usingmultiple magnetic tunnels. Disclosed are various embodiments for amotor/generator comprising: a plurality of coils radially positionedabout a coil assembly, a plurality of magnetic tunnels forming arelative rotational path for the coil assembly, wherein the all ofplurality of magnets forming each magnetic tunnel have like poles facinginward toward the interior of the magnetic tunnel or facing outward awayfrom the interior of the magnetic tunnel such that each magnetic fieldof any magnetic tunnel is of an opposite polarity to the magnetic fieldof an adjacent magnetic tunnel.

These and other features, and advantages, will be more clearlyunderstood from the following detailed description taken in conjunctionwith the accompanying drawings. It is important to note the drawings arenot intended to represent the only aspects of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an exploded view of one embodiment of a motor/generatorcomponent according to certain aspects of the present disclosure.

FIG. 1B is a detailed exploded view of certain elements of themotor/generator component of FIG. 1A.

FIG. 2 is a detailed isometric view of a magnetic cylinder/statorelement or magnetic cylinder/rotor element of the motor/generatorcomponent illustrated in FIG. 1A.

FIG. 3 is an exploded view of the magnetic cylinder/stator element orthe magnetic cylinder/rotor element of FIG. 2.

FIG. 4A is an isometric view of a partial coil assembly element.

FIG. 4B is a detailed perspective view of a single tooth element of thepartial coil assembly element illustrated in FIG. 4A.

FIG. 4C is a detailed perspective view of an alternative embodiment of asingle tooth element of the partial coil assembly element illustrated inFIG. 4A.

FIG. 4D is an isometric view of the partial coil assembly element ofFIG. 4A coupled to a plurality of coil windings.

FIG. 4E is an isometric view of a coil assembly.

FIG. 5 illustrates one embodiment of a toroidal magnetic cylinder.

FIG. 6 illustrates a conceptual two-dimensional radial segment of atoroidal magnetic cylinder.

FIG. 7A is a detailed isometric view of one embodiment of a radialportion or radial segment of the toroidal magnetic cylinder illustratedin FIG. 5.

FIG. 7B is a detailed isometric view of one embodiment of the radialportion or radial segment illustrated in FIG. 7A with the addition ofdirection arrows.

FIG. 7C is a detailed isometric view of one embodiment of the radialportion or radial segment illustrated in FIG. 7A with the addition of aportion of a coil assembly illustrated in FIG. 4E.

FIG. 7D illustrates one embodiment of the coil assembly of FIG. 4Epositioned within the toroidal magnetic cylinder of FIG. 5.

FIG. 8 illustrates the magnetic cylinder of FIG. 7D coupled to a backiron circuit with a portion of the side back iron circuit positioned inan exploded view for clarity.

FIG. 9A is an exploded view of the magnetic cylinder and back ironcircuit of FIG. 8 coupled to additional structures to form amotor/generator.

FIG. 9B is an isometric view of the magnetic cylinder and back ironcircuit of FIG. 8 coupled to additional structures to form amotor/generator.

FIG. 10 is an alternative exploded view of the motor/generator of FIGS.9A and 9B illustrating the stationary and rotating elements.

FIG. 11 is a perspective view of a rotor hub and certain elements of themotor/generator.

DETAILED DESCRIPTION

Specific examples of components, signals, messages, protocols, andarrangements are described below to simplify the present disclosure.These are, of course, merely examples and are not intended to limit theinvention from that described in the claims. Well-known elements arepresented without detailed description in order not to obscure thepresent invention in unnecessary detail. For the most part, detailsunnecessary to obtain a complete understanding of the present inventionhave been omitted inasmuch as such details are within the skills ofpersons of ordinary skill in the relevant art. Details regardingconventional control circuitry, power supplies, or circuitry used topower certain components or elements described herein are omitted, assuch details are within the skills of persons of ordinary skill in therelevant art.

When directions, such as upper, lower, top, bottom, clockwise, orcounter-clockwise are discussed in this disclosure, such directions aremeant to only supply reference directions for the illustrated figuresand for orientation of components in the figures. The directions shouldnot be read to imply actual directions used in any resulting inventionor actual use. Under no circumstances, should such directions be read tolimit or impart any meaning into the claims.

Motor/Generator Element and Back Iron Circuit

FIG. 1A is an exploded isometric view of a motor/generator element 100illustrating a first portion 202 of a back iron circuit 200, a secondportion 204 of the back iron circuit 200, a rotor hub 300, and amagnetic disc assembly 400.

The back iron circuit 200 is theoretically optional. It serves tostrengthen magnetic elements (described below) and constrain themagnetic circuit to limit reluctance by removing or reducing the returnair path. The first portion 202 of the back iron circuit 200 comprises afirst outer cylindrical wall 206 made of a suitable back iron materialas described below. When the motor/generator element 100 is assembled, afirst inner cylindrical wall 208 is concentrically positioned within thefirst outer cylindrical wall 206. A first flat side wall 210 which isalso made of back iron material is positioned longitudinally next to thefirst outer cylindrical wall 206 and the first inner cylindrical wall208.

A second portion of the back iron circuit includes a second innercylinder wall 218 concentrically positioned within a second outercylindrical wall 216 (when the motor/generator element 100 isassembled). A second flat side wall 220 of back iron material ispositioned longitudinally next to the second outer cylindrical wall 216and the second inner cylindrical wall 218. In certain embodiments, thesecond inner cylinder wall 218 and second outer cylinder wall 216 have aplurality of longitudinal grooves sized to accept and support aplurality of magnets as described below with respect to FIG. 1B.

For purposes of this application the term “back iron” may refer to iron,an iron alloy, any ferrous compound or alloy, such as stainless steel,any nickel or cobalt alloy, laminated steel, laminated silicon steel, orany laminated metal comprising laminated sheets of such material, or asintered specialty magnetic powder. In some embodiments, the ring core504 may be hollow or have passages defined therein to allow for liquidor air cooling.

In certain embodiments, there is a radial gap 212 between the firstouter wall 206 and the first side wall 210. The radial gap 212 allowsfor the passage of a support structure, control wires and electricalconductors (not shown) into the magnetic disc assembly 400 as well asfor heat dissipation and/or a thermal control medium. In otherembodiments, the gap 212 may be defined within the first outer wall 206or between the first outer wall 206 and the second outer wall 216. Inyet other embodiments, the gap 212 may be located in other locations tooptimize performance.

FIG. 1B is a detailed isometric view of the first portion 202 of theback iron circuit illustrating the first inner cylindrical wall 208,positioned within the first outer cylinder wall 206. A plurality ofinner longitudinal grooves 240 are defined and radially spaced around aninner surface 242 of the first outer cylinder wall 206. Similarly, aplurality of outer longitudinal grooves 244 are defined and radiallyspaced around an outer surface 246 of the first inner cylinder wall 208.

As will be described in detail below, a plurality of outer magnetsforming a portion of an outer magnetic wall 406 a (from the magneticdisc 400 discussed below) are sized to fit within the plurality of innerlongitudinal grooves 240. Similarly, a plurality of inner magnetsforming a portion of an inner magnetic wall 408 a are sized to fitwithin the plurality of outer longitudinal grooves 244 defined withinthe outer surface 246 of the first inner cylinder wall 208. Similar oridentical grooves or surfaces are found in the second portion 204 of theback iron circuit 200, and thus, will not be separately described inthis disclosure.

When the motor/generator element 100 is assembled, the first portion 202of the back iron circuit 200 and the second portion 204 of the back ironcircuit physically support and surround the magnetic disc 400. The firstinner wall 208 and second inner wall 218 also radially surrounds and isradially coupled to the rotor hub 300. In certain embodiments, the rotorhub 300 positions and structurally supports certain components of theback iron circuit 200 (which in turn, supports the magnetic componentsof the magnetic disc 400).

Magnetic Disc Assembly

FIG. 2 is a detailed isometric view of the assembled magnetic disc 400of FIG. 1. FIG. 3 is an exploded view of the magnetic disc 400. In theembodiment illustrated in FIGS. 2 and 3, with respect to a longitudinalaxis 401, there is a top or first axial or side wall of magnets 402.Similarly there is a bottom or second axial or side wall of magnets 404.An outer cylindrical wall of magnets 406 is longitudinally positionedbetween the first axial or side wall 402 and the second axial or sidewall of magnets 404. In certain embodiments, the outer cylindrical wallof magnets 406 comprises two pluralities of magnets 406 a and 406 bwhich are sized to couple with the back iron walls 206 and 216, asdescribed above with respect to FIG. 1B.

An inner cylindrical wall of magnets 408 is also longitudinallypositioned between the first axial or side wall 402 and the second axialor side wall of magnets 404 and concentrically positioned within theouter cylindrical wall of magnets 406. In certain embodiments, the innercylindrical wall of magnets 408 comprises two pluralities of magnets 408a and 408 b which are sized to couple with the back iron walls 208 and218, as described above in reference to FIG. 1B.

In certain embodiments, the magnets forming the axial side walls 402-404and cylindrical walls 408-406 discussed herein may be made of out anysuitable magnetic material, such as: neodymium, Alnico alloys, ceramicpermanent magnets, or electromagnets. The exact number of magnets orelectromagnets will be dependent on the required magnetic field strengthor mechanical configuration. The illustrated embodiment is only one wayof arranging the magnets, based on certain commercially availablemagnets. Other arrangements are possible, especially if magnets aremanufactured for this specific purpose.

Coil Assembly

When the motor/generator 100 is assembled, a coil assembly 500 isconcentrically positioned between the outer cylinder wall 406 and theinner cylinder wall 408. The coil assembly 500 is also longitudinallypositioned between the first axial side wall 402 and the second axialside wall 404. In certain embodiments, the coil assembly 500 may be astator. In yet other embodiments, the coil assembly 500 may be a rotor.

Turning now to FIG. 4A, there is an isometric view of a coil assemblysupport 502, which in one embodiment, may be a portion of a stator usedin conjunction with a rotor formed by the magnetic axial walls 402-404and magnetic longitudinal walls 406-408 and the back iron circuitportions 202 and 204 discussed above in reference to FIGS. 1A through 3.In certain embodiments, the coil assembly support 502 comprises acylindrical or ring core 504 coupled to a plurality of teeth 506radially spaced about the ring core. FIG. 4A shows a portion of teeth506 removed so that the ring core 504 is visible.

In certain embodiments, the ring core 504 and coil assembly support 502may be made out of iron or back iron materials so that it will act as amagnetic flux force concentrator. Some back iron materials are listedabove. However, other core materials maybe used when designconsiderations such as mechanical strength, reduction of eddy currents,cooling channels, etc. are considered.

In yet other embodiments, the coil assembly support 502 may be made froma composite material which would allow it to be sculptured to allow forcooling and wiring from inside. The composite material may be formed ofa “soft magnetic” material (one which will produce a magnetic field whencurrent is applied to adjoining coils). Soft magnetic materials arethose materials which are easily magnetized or demagnetized. Examples ofsoft magnetic materials are iron and low-carbon steels, iron-siliconalloys, iron-aluminum-silicon alloys, nickel-iron alloys, iron-cobaltalloys, ferrites, and amorphous alloys.

In certain embodiments, a wiring connection (not shown) can also beformed in the shape of a “plug” for coupling to the stator teeth. Thus,certain teeth of the plurality of teeth 506 may have holes 508 for suchplugs (or wires) defined on one side for attachment to a structuralsupport in embodiments where the coil assembly 500 acts as a stator asdescribed below in reference to FIGS. 9A-11.

One embodiment of an individual tooth 506 a and a small portion of thering core 504 are illustrated in FIG. 4B. The tooth 506 a may be madefrom a material similar to the material forming the core 504, forexample, iron, a composite magnetic material, or laminated steel. In theillustrated embodiment, each tooth 506 a extends from the ring core 504in radial and vertical (or longitudinal) directions. Thus, each tooth506 a comprises an outer radial portion 510 extending radially away fromthe longitudinal axis 401 (see FIG. 4A), an inner radial portion 512extending radially toward the longitudinal axis 401, a top vertical orlongitudinal portion 514 extending in one vertical or longitudinaldirection, and a bottom vertical or longitudinal portion 516 extendingin the opposing longitudinal direction. The ring core 504 supports theindividual tooth 506 a as well as other teeth as described above inreference to FIG. 4A.

In certain embodiments, an exterior fin 520 couples to an exteriorportion of the outer radial portion 510 and extends outward from theouter radial portion 510 in both circumferential or tangentialdirections with respect to the longitudinal axis 401. Similarly, aninterior fin 522 couples to an interior portion of the inner radialportion 512 and extends outward from the inner radial portion 512 inboth tangential directions.

An alternative embodiment of an individual tooth 506 a′ and a smallportion of the ring core 504 are illustrated in FIG. 4C. The tooth 506a′ is similar to the tooth 506 a described above in reference to FIG. 4Bexcept that the tooth 506 a′ also has radial or horizontal finsextending from the top vertical portion 514 and the lower verticalportion 516. Specifically, a top radial fin 518 extends in bothhorizontal circumferential (or tangential) directions from the tophorizontal portion 514 and connects the exterior fin 520 to the interiorfin 522. Similarly, a bottom radial fin 519 extends in both horizontalcircumferential or tangential directions from the bottom verticalportion 516 and connects the exterior fin 520 to the interior fin 522 asillustrated in FIG. 4C.

Adjacent teeth 506 (or adjacent teeth 506 a′) supported by the core ring504 form radial slots 524 within the coil assembly support structure502, as illustrated in FIG. 4A. A plurality of coils or coil windings526 may be positioned radially about the ring core 504 and within theslots 524 as illustrated in FIG. 4D. FIG. 4D illustrates the pluralityof coil windings 526 distributed about the ring core 504 with a numberof teeth 506 removed for clarity. In contrast, FIG. 4E illustrates acomplete coil assembly 500 showing all of the teeth 506 and coilwindings 526 positioned within the slots 524.

Coils or Coil Windings

Each individual coil 526 in the coil assembly 500 may be made from aconductive material, such as copper (or a similar alloy) wire and may beconstructed using conventional winding techniques known in the art. Incertain embodiments, concentrated windings may be used. In certainembodiments, the individual coils 526 may be essentially cylindrical orrectangular in shape being wound around the ring core 504 having acenter opening sized to allow the individual coil 526 to surround and besecured to the ring core 504. Thus, in such embodiments, the windingdoes not overlap.

By positioning the individual coils 526 within the slots 524 defined bythe teeth 506, the coils are surrounded by the more substantial heatsink capabilities of the teeth which, in certain embodiments, canincorporate cooling passages directly into the material forming theteeth. This allows much higher current densities than conventional motorgeometries. Additionally, positioning the plurality of coils 526 withinthe slots 524 and between teeth 506 reduces the air gap between thecoils. By reducing the air gap, the coil assembly 500 can contribute tothe overall torque produced by the motor or generator.

In certain embodiments, the horizontal fins 518 and 519, thecircumferential fins 520 and 522 of the teeth 506 a or 506 a′ of thecoil assembly reduce the air gaps between the magnetic material and thecoil structure to allow flux forces to flow in the proper direction whenthe coils are energized and the coil assembly 500 begins to moverelative to the magnetic tunnel. Thus, all portions of the coil supportassembly 502 contribute to the overall torque developed by the system.In yet other embodiments, the teeth 506 may not have any fins. Althoughthe fins create a more efficient design, the fins complicate thefabrication of the coil windings, thereby increasing the motor costs.Unconventional winding techniques may be used when using fins—such asfabricating the coil assembly support 502 in conjunction with the coilwindings. In some embodiments, a winding may be started at the center ofthe conductor length with two bobbins rotating in opposite directionsaround the core with the wound segments in separate parallel planes.This method has the advantage of both conductor ends exiting at the samelocation and eliminating compression of one conductor length exitingfrom the center of the winding.

The number of individual coils 526 can be any number that willphysically fit within the desired volume and of a conductor length andsize that produces the desired electrical or mechanical output as knownin the art. In yet other embodiments, the coils 526 may be essentiallyone continuous coil, similar to a Gramme Ring as is known in the art.

The windings of each coil 526 are generally configured such that theyremain transverse or perpendicular to the direction of the relativemovement of the magnets (e.g. the rotor) comprising the coil assembly500 and parallel with the longitudinal axis 401. In other words, thecoil windings are positioned such that their sides are parallel with thelongitudinal axis 401 and their ends are radially perpendicular to thelongitudinal axis. As will be explained below, the coil windings arealso transverse with respect to the magnetic flux produced by theindividual magnets of the rotor at their interior face as describedbelow in reference to FIG. 7A to 7C. Consequently, the entire coilwinding or windings may be used to generate movement (in motor mode) orvoltage (in generator mode).

In sum, the windings are placed in an axial/radial direction in multipleslots 524 (e.g. 48 slots) which can form a single phase or multi-phasewinding. The radial/axial placement of the windings may create a maximumforce in the direction of motion for all four sides of the windings.

The Magnetic Cylinder

FIG. 5 is an isometric view of the magnetic disc assembly 400 with thecoil assembly 500 removed for clarity. The magnets of the magnetic discassembly 400 form a toroidal magnetic cylinder 430 defining a toroidalmagnetic tunnel 440 positioned about the longitudinal axis 401. Asdescribed previously, the toroidal magnetic cylinder 430 includes: thetop axial or side wall of magnets 402, the bottom or second axial orside wall of magnets 404, the outer cylindrical wall 406 of magnetspositioned longitudinally between the first side wall 402 of magnets andthe second side wall 404 of magnets; and the inner cylindrical wall 408of magnets positioned concentrically within the outer cylindrical wall406 of magnets. In certain embodiments, the outer cylindrical wall 406may be formed by two pluralities of magnets 406 a and 406 b, where eachplurality of magnets are sized to couple with the back iron circuitwalls 206 and 216, respectively. Similarly, the inner cylindrical wall408 may be formed by two pluralities of magnets 408 a and 408 b, whereeach plurality of magnets are sized to couple with the back iron circuitwalls 208 and 218, respectively.

As discussed above with respect to the back iron circuit 200, dependingon the embodiment, there may be a radial circumferential slot 410defined by the outer longitudinal ring of magnets 406 and one of theside walls 402 or 404 to accommodate a support structure for the statorand/or control wires, conductors, ventilation and/or a cooling medium.In other embodiments, there may be a circumferential slot separating theouter cylinder wall 406 of magnets into a first longitudinal ring 406 aand a second longitudinal ring 406 b of magnets. In yet otherembodiments, there may be a circumferential slot separating the innercylinder wall 408 of magnets into a first longitudinal ring 408 a and asecond longitudinal ring 408 b of magnets. In yet further embodiments, acircular slot may be defined anywhere within the side walls 402 or 404.

In the embodiment illustrated in FIG. 5, the magnetic side walls 402,404 and the magnetic cylindrical walls 406 and 408 may be made fromcommercially available magnetic segments. In other embodiments, platemagnets may be customized for a particular application. The number ofsegments forming the rings or walls will depend on the particular designand performance characteristics for a particular application.

Note that in the illustrative embodiment of FIG. 5, there are eightradial “slices” or magnetic segments 420 forming a complete toroidalmagnetic cylinder 430. However, the exact number of segments depends onthe size, performance characteristics, and other design factors.

FIG. 6 is a cross-sectional conceptual view of one embodiment of aradial “slice” 150 of a magnetic cylinder which is conceptually similarto the radial segment 420 of the toroidal magnetic cylinder 430 of FIG.5 above. In certain embodiments, the partial magnetic cylinder 150comprises an outer curved wall 102 and an inner curved wall 104. Theouter curved wall 102 and inner curved wall 104 may be made with aplurality of magnets. In a lateral section view, such as illustrated inFIG. 6, it can be seen that the outer curved wall 102 is comprised of aplurality of magnets 106, comprising individual magnets, such as magnets106 a, 106 b, 106 c, etc. Similarly, the inner curved wall 104 may becomprised with a plurality of magnets 108, comprising individual magnets108 a, 108 b, etc. It should be noted that only one polarity of themagnets are utilized within (or facing into) the magnetic cylinderportion 150. For instance in the illustrative embodiment of FIG. 6, thenorth poles of the magnets 106 are each pointing radially towards thecenter or longitudinal axis 401 (which is coming out of the page in FIG.6). On the other hand, the north poles of the magnets 108 each pointradially away from the longitudinal axis 401 and towards an interiorcavity or tunnel 124 of the partial magnetic cylinder 150.

In certain embodiments, there may be a central core, such as an ironcore (not shown in FIG. 6), where a portion of the core is positionedwithin the interior tunnel 124 between the outer wall 102 and the innerwall 104. In certain embodiments, the core may be used as a magneticflux line concentrator.

When the plurality of magnets 106 and 108 are arranged into the outerwall 102 and inner wall 104 to form a partial cylinder 150, the densityof the magnetic flux forces will form particular patterns as representedin a conceptual manner by the flux lines 112 illustrated in FIG. 6. Theactual shape, direction, and orientation of the flux lines 112 depend onfactors such as the use of an interior retaining ring, a center core, aback iron circuit, material composition and/or configuration.

To generally illustrate this magnetic arrangement, the flux line 112 a(or flux lines) from the magnet 106 a of the exterior wall 102 tends toflow from the north pole (interior face) of the magnet in aperpendicular manner from the face of the magnet into and through theinterior tunnel 124 of the partial cylinder 150, exiting through theopen end 114 into the open area 115, then flow around the exterior ofthe partial cylinder 150, and back to an exterior face of the magnet 106a containing its south pole.

Similarly, the flux line 112 b from the magnet 106 b of the exteriorwall 102 tends to flow from the north pole of the magnet in aperpendicular manner from the face of the magnet into and through theinterior tunnel 124 of the partial cylinder 150, exiting through theopen end 114 into the open space 115, then flow around the exterior ofthe cylinder 150, and back to the face of the magnet 106 b containingits south pole. Although only a few flux lines 112 are illustrated forpurposes of clarity, each successive magnet in the “top portion” of theplurality of magnets will produce similar flux lines. Thus, the magneticflux forces for each successive magnet in the plurality of magnets 106tend to follow these illustrative flux lines or patterns for eachsuccessive magnetic disc in the plurality of magnets 106 until themagnets at the open ends 114 or 116 of the partial magnetic cylinder 150are reached.

As illustrated, the magnet 106 a is positioned circumferentiallyadjacent to the magnet 106 b. In turn, another magnet 106 c ispositioned circumferentially adjacent to the magnet 106 b. Additionalmagnets in the group 106 may be positioned circumferentially adjacent toothers until the open end 114 is reached. The flux lines 112 generatedfrom the adjacent magnetic poles in the magnetic group 106 areconcentrated at the open ends of the tunnel segment where they turn backtowards an exterior face of the respective magnet.

Magnets in the “bottom portion” of the plurality of magnets 106, such asmagnet 106 d tend to generate flux lines 112 d from the magnet 106 d onthe exterior wall 102 which tends to flow from the north pole (interiorface) of the magnet in a perpendicular manner from the face into andthrough the interior tunnel 124 of the partial cylinder 150, exitingthrough an open end 116 into the open space, then flow around theexterior of the partial cylinder 150, and back to an exterior face ofthe magnet 106 d containing its south pole. Although only a few fluxlines on the opposing side of the partial cylinder 150 are illustratedfor purposes of clarity, each successive or magnet in the plurality ofmagnets will produce similar flux lines which will also be concentratedat the opening 116 as described above. In embodiments with an iron core,the flux lines will generally flow in a similar manner, but will tend toflow through the core and be concentrated within the core. Thus, incertain embodiments, the core may act as a flux concentrator.

The interior magnetic wall 104 also produces flux forces, which also maybe illustrated by flux lines, such as exemplary flux lines 118. Forinstance, the flux line 118 a from the magnet 108 a on the interior wall104 tends to flow from interior face (e.g., the north pole) in aperpendicular manner from the face of the magnet, into and through theinterior tunnel 124 of the partial cylinder 150, out the open end 114(or open end 116) and into the open space 115, then around the interiorwall 104 to the face of the magnet 108 a containing its south pole.

The magnetic flux forces for each successive magnet in the plurality ofmagnets 108 tend to follow these illustrative flux lines or patterns 118for each successive magnet in the plurality of magnets 108 until theopen ends 114 or 116 of the partial magnetic cylinder 150 are reached.Thus, the flux forces produced by the magnets of the interior wall 104of the partial cylinder 150 have an unobstructed path to exit throughone of the open ends of the partial cylinder and return to its opposingpole on the exterior or interior of the cylinder.

As discussed above, the magnetic flux lines 112 and 118 will tend todevelop a concentrating effect and the configuration of the exteriormagnetic cylinder manipulates the flux lines 112 and 118 of the magnetsin the partial magnetic cylinder 150 such that most or all of the fluxlines 112 and 118 flow out of the open ends 114 and 116 of the partialcylinder. In conventional configurations, the opposing poles of themagnets are usually aligned longitudinally. Thus, the magnetic fluxlines will “hug” or closely follow the surface of the magnets. So, whenusing conventional power generating/utilization equipment, theclearances must usually be extremely tight in order to be able to act onthese lines of force. By aligning like magnetic poles (e.g. (all southor all north) radially with respect to the longitudinal axis 401, themagnetic flux lines 112 and 118 tend to radiate perpendicularly from thesurface of the magnets. This configuration allows for greater tolerancesbetween coils and the partial magnetic cylinder 150.

The partial magnetic cylinder 150 is a simplified two dimensionalsection illustration of a three dimensional magnetic arrangementconcept. The three dimensional arrangement also has magnetic top andbottom magnetic walls with their north magnetic poles facing theinterior of the tunnel 124 (not shown). Additionally, similar resultscan be obtained by replacing the plurality of magnets 106 with a singlecurved plate magnet magnetized in a similar manner (e.g., a north poleis formed on the interior face and a south pole is formed on an exteriorface). Similarly, the plurality of magnets 108 may be replaced with asingle curved plate magnet having its north pole on the surface facingthe interior tunnel 124 and the south pole on the surface facing towardsthe longitudinal axis 401.

For instance, FIG. 7A is a detailed perspective view of the radialsegment 420 of the toroidal magnetic cylinder 430 (see FIG. 5) defininga portion of the magnetic tunnel 440 as discussed above in reference toFIG. 5. The radial segment 420 is conceptually similar to the partialmagnetic cylinder 150 because the radial segment 420 has an outer curvedmagnetic wall 406 and an inner curved magnetic wall 408. In addition tothe curved or cylindrical magnetic walls 406 and 408, there are alsomagnetic axial or lateral walls 402 and 404 which in this illustratedembodiment may be made of wedge shaped plate magnets.

The magnetic poles of the magnets forming the outer cylindrical wall 406and the inner cylindrical wall 408 have their magnetic poles orientatedradially pointing towards the longitudinal axis 401 (see FIG. 5). Incontrast, the magnetic poles of the magnets forming the top or firstaxial wall 402 and the bottom or second axial wall 404 have theirmagnetic poles orientated or aligned parallel with the longitudinal axis401. The individual magnets in the magnetic walls 402, 404, 406, and 408all have their similar or “like” (e.g. north) magnetic poles orientatedeither towards or away from the interior of the tunnel 440 of thetoroidal magnetic cylinder 430 to form a “closed” magnetic tunnel 440.The closed magnetic tunnel 440 runs circumferentially from the open endor exit 412 to the open end or exit 414 (similar to the tunnel 124 andopen ends 114 and 116 discussed above with reference to FIG. 6).

For purposes of this disclosure and to illustrate the orientation ofmagnetic poles at the surfaces of the magnets forming the radial segment420, the top axial wall 402 is labeled with an “S” on its exterior topface to indicate that in this particular configuration, the south poleof the magnet (or magnets) forming the top axial wall 402 faces awayfrom the tunnel 440. Thus, the north pole of the magnet 402 facestowards the tunnel segment 440. Similarly, the lower axial or side wall404 is labeled with a “N” on its interior side face to indicate that thenorth pole of the magnet forming the side wall 404 is facing towards thetunnel segment 440 (however, in this view the “N” is partiallyobscured). The two magnets forming the outer longitudinal wall 406 arelabeled with an “N” on their interior surfaces to indicate that theirnorth magnetic poles face the interior of the magnetic tunnel 440. Incontrast, the two magnets forming the inner longitudinal wall 408 arelabeled with an “S” on their exterior surfaces to indicate that theirsouth poles are facing away from the tunnel 440. Thus, their north polesface towards the tunnel 440.

In this illustrative embodiment of the radial segment 420, all themagnets of the walls 402, 404, 406 and 408 have their north poles facingtowards the interior or tunnel 440. So, the radial segment 420 has anNNNN magnetic pole configuration. Thus, the magnetic forces which tendto repel each other—forcing the magnetic flux circumferentially alongthe tunnel 440 in a circumferential direction and out the tunnel exits412 and 414 similar to that described above in reference to FIG. 6. FIG.7B is an illustration of the radial segment 420, but with the additionof directional arrows. Arrow 422 illustrates a circumferential directionand the arrow 424 illustrates a radial direction.

The term “closed magnetic tunnel” as used in this disclosure refers tousing an arrangement of the magnets forming a tunnel that “forces” or“bends” the majority of the magnetic flux “out of plane” orcircumferentially through the tunnel or interior cavity then out throughone of the openings 412 or 414 as illustrated by the circumferentialarrow 422 of FIG. 7B. In contrast, if the magnetic tunnel were notmagnetically “closed,” the flux forces would generally flow in a radialmanner in the direction of the radial or lateral arrow 424 (or in aplane represented by the arrow 424). Conventional motors usually allowflux forces to flow in a radial direction as illustrated by the arrow424.

Turning now to FIG. 7C, there is illustrated an isometric view of radialsegment 420 with a portion of the coil assembly 500 positioned withinthe interior of the segment or tunnel 440 (FIG. 5B). The rest of thecoil assembly 500 has been removed for clarity. In an un-energizedstate, the magnetic flux tends to flow from the north poles of themagnetic walls 402, 404, 406 and 408 into the coil assembly 500 and tothe coil core 504. Because of opposing magnetic forces, the magneticflux continues to flow circumferentially through the coil core 504 untilthe flux reaches an opening (for instance, open end 414) of the tunnel440. The flux then bends back around an open end (e.g. open end 414) ofthe radial segment 420 to an exterior face of the respective magneticwall containing a south pole. Arrows 426 of FIG. 7C are meant toillustrate the three dimensional flux path as the flux reaches an openend 412 or 414 of the radial segment and bends back around to anexterior face (or in this case, the south pole) of the appropriatemagnetic wall. Thus, the radial segment 420 generates a flux field whichis conceptually similar to the flux fields 112 and 118 discussed abovein reference to FIG. 6 (In situations where a radial segment 420 isadjacent to another radial segment of an opposite magnetic polarityconfiguration, the flux lines could extend into the adjacent partialtoroidal magnetic cylinder).

In certain embodiments, the core 504/coil assembly 500 may generate itsown magnetic field fluxes as current is introduced into the supportingcoils 526 (FIG. 4D). The majority of magnetic field fluxes are alsoconstrained and channeled to interact with the magnetic flux generatedfrom the magnetic tunnel (e.g., from permanent magnets) in a similarmanner to that described above. Thus, all portions of the coil 504/coilassembly 500 may interact with the flux lines of the magnetic tunnel 440to allow full utilization of the flux lines and all forces workingtogether in the direction of motion.

As opposed to “pancake style” or axial flux electric motor, thelongitudinal length or “width” of the outer walls 406 and 408 aregreater than the radial or lateral depth (or length) of the side walls402 and 404 as illustrated in FIGS. 7A-7C. This geometric proportionresults in greater torque generation along the interface of the outerwall 406 and coil assembly 502. In certain alternate embodiments, thethickness of the magnets comprising the outer wall 406 may also beincreased to increase the generation of torque. In any event, thecontribution to torque from the outer wall 406 and the inner wall 408may be greater than the contribution from the side walls 402 and 404 dueto the geometry of the cross-section of the radial segment 420 and thevarying radius of the components.

Although the core, coil assembly, and magnetic radial segments areillustrated in cross-section as rectangular, any cross-sectional shapemay be used depending on the design and performance requirements for aparticular motor or generator. In a preferred embodiment, there is moremagnetic material positioned in or along an outer wall (such as themagnetic wall 406) along the longitudinal direction than magneticmaterial positioned in or along a radial wall (such as the axial or sidewalls 402 or 408). For instance, if the magnets forming the magneticwalls are all the same thickness, the length of the outer wall in thelongitudinal direction is greater than the length of the axial or sidewalls in the radial direction. In alternative embodiments, the length ofthe magnets forming the outer magnetic wall may be the same or shorterthan the length of the magnets forming the axial or side walls.

The unique configurations illustrated in FIGS. 7A-7C also leads toseveral unique properties. For instance, an individual coil 526 and coreportion 504 will tend to move out of the tunnel 440 on its own accord(e.g. with no power applied). The natural tendency of this configurationis for the coil 526 to follow the flux lines to the nearest exit 412 or414. Conversely if a current is applied the coil 526, the coil 526 willmove though the entirety of the magnetic tunnel depending on polarity ofthe power applied. The encapsulation of the coil 526 in the magneticflux of the magnetic tunnel 440 also allows all magnetic fields to beused to generate motor or electric power. Cogging effects can be reducedas the coil will tend to travel out of the tunnel when no currentapplied. This also means that the coil 526 does not have to be pulsedwith an opposing magnetic field at any point while in the magnetictunnel 440. Additionally, the coil 526 will travel through the entiremagnetic tunnel 440 length with a single DC pulse of the correctpolarity. Non-sinusoidal torque or voltage is generated throughout theduration of time that the coil 526 is under the influence of themagnetic tunnel 440 and alternating polarities are not required for thiseffect to occur.

As illustrated in FIG. 7D, the illustrative embodiment of the toroidalmagnetic cylinder 430 comprises eight radial segments where four radialsegments 421 are interspersed between the four radial segments 420. Thefour radial segments 421 are identical to the radial segments 420 exceptthat the magnetic pole orientation of the magnets has been reversed. So,in the radial segment 420, all of the interior facing magnetic poles arenorth forming a NNNN magnetic tunnel configuration as illustrated inFIG. 7A. In contrast, in the radial segment 421, all of the interiorfacing magnetic poles are south forming a SSSS magnetic tunnelconfiguration. Thus, the tunnels radial segments 420 generate fluxfields which are of an opposite polarity to the flux fields generated bythe radial segments 421. In traditional motor terminology, each radialsegment is a motor magnet pole. Thus, each radial segment is a threedimensional magnetic pole which can create a three dimensional symmetricmagnetic field. Alternating the segments then produces a sinusoidalfield.

With regard to the toroidal magnetic cylinder 430, each magnetic orradial segment (e.g. radial segments 420 or 421) has their respectivemagnetic configuration (NNNN or SSSS) of like magnetic polaritiesreversed for each adjacent radial segment. Although, an eight segmenttoroidal magnetic cylinder 430 is illustrated in FIG. 7D, in otherembodiments, two, four, six, ten, etc. segments may be used. The numberof segments selected for any given application may be based onengineering design parameters and the particular performancecharacteristics for an individual application. The scope of thisinvention specifically includes and contemplates multiple segmentshaving an opposite polarity to the adjacent partial toroidal magneticcylinders. For simplicity and illustrative purposes, an eight segmenttoroidal magnetic cylinder is described herein. However, this designchoice is in no way meant to limit the choice or number of segments forany multi-segment toroidal magnetic cylinder.

In certain embodiments, the radial segments 420 and 421 may be sized toallow radial gaps 416 to form when the partial toroidal magneticcylinders are assembled into the complete cylinder 430 as illustrated inFIG. 7D.

As described above, in certain embodiments, the individual magnetsforming the toroidal magnetic cylinder 430 couple to various componentsof the back iron circuit 200. The back iron circuit 200 may be used tochannel part of the magnetic flux path.

The Integrity of the Magnetic Tunnel

As described above in reference to FIGS. 6, 7A-7C, by surrounding a coilon all sides with “like” polarity magnets (e.g. all north poles or allsouth poles), the flux lines from those magnets are forced to travelthrough the center of the “magnetic tunnel” 404 formed by thesurrounding magnets—along the radial or circumferential direction 422(FIG. 7B) and eventually exit at the mouth or open ends 412 and 414 ofthe tunnel 440 (see FIG. 7C). The natural tendency of the flux lines isto flow along the shortest path—which is usually in the radial, lateralor “sideways” direction 434 (see FIG. 7B). Although some flux leakagemay be acceptable, if the flux leakage is large, the integrity of themagnetic tunnel 440 will be compromised and the flux lines will nolonger travel in the circumferential direction. If the flux lines do nottravel in the circumferential direction, many of the advantages ofcertain embodiments will be lost.

As illustrated in FIG. 7A for instance, there are a number of slots or“gaps” between the magnet walls, such as the circumferential slot 410 orslot 411. These gaps may be carefully controlled or too much flux willleak through the gaps and essentially destroy the magnetic fluxintegrity of the magnetic tunnel 440. In an ideal world, there would beno slots or gaps in the tunnel and thus, it would be impossible for theflux lines to escape laterally. However, if there were no slots, itwould be difficult to support the coil assembly and to providingelectrical and cooling conduits to the coil assembly.

One method of controlling gap flux leakage is to limit the lateral widthof the gaps. For instance, the total length of the sides of the“magnetic tunnel” may be substantially larger than the circular supportmechanism slot and the slot reluctance may be high enough to force acircumferential magnetic flux field to form in the magnetic tunnel 440.As an example, limiting the lateral width of the circumferential slotsto roughly a ratio of 1 unit of slot width to every 12 units ofcircumference/perimeter length may provide enough transverse flux linesto steer the majority of the flux lines along the circumferentialdirection 422 as discussed above.

Another solution is placing another group or group of magnets in closeproximity with the slots such they generate an addition flux field linesacross the gap or slot. For instance, two groups of magnets positionedon either side of coil assembly may produce enough “cross flux” to keepthe flux in the magnetic tunnel from escaping. A magnet on one side ofthe slot may have its north pole facing the slot. An opposing magnet onthe other side of the slot may have is south pole facing the slot. Thus,cross flux lines from the north pole to the south pole would begenerated across the slot.

In one embodiment, permanent magnets orientated to provide a cross fluxmay be embedded in a coil assembly supporting structure or embedded inthe back iron material. In other embodiments, powdered magnetic materialmay be used. In yet other embodiments, strongly diamagnetic materials(Pyrolytic carbon and superconductor magnets have been shown to becapable of rejecting force lines, and thus could be used.

Defining the Flux Path with the Back Iron Circuit

FIG. 8 is an isometric view illustrating the coil assembly 500positioned within the toroidal magnetic cylinder 430 which is coupled toand surrounded by the back iron circuit 200. The first flat side wall210 has been repositioned in an exploded view for clarity. As describedabove, in the illustrative embodiment, the back iron circuit 200 mayinclude a first side or axial wall 210 and the second side or axial wall220. In this embodiment, the first outer cylindrical wall 206 and thesecond outer cylindrical wall 216 forms and couples to and surrounds theouter magnetic walls 406 a and 406 b of the toroidal magnetic cylinder430, respectively (see FIG. 5). The first inner cylindrical wall 208 andthe second inner cylindrical wall 218 is coupled to and surrounded bythe inner wall magnets 408 a-408 b of the toroidal magnetic cylinder 430(see FIG. 5). Thus, the entire back iron circuit 200 includes the innercylindrical walls 208 and 218, the outer cylindrical walls 206 and 216,and the side or axial walls 210 and 220 as illustrated in FIG. 8. Incertain embodiments, the back iron circuit 200 combined with thetoroidal magnetic cylinder 430 may form a rotor (or a stator dependingon the motor configuration). In certain embodiments, the back ironcircuit 200 may be used to channel part of the magnetic flux path. Theback iron material channels the magnetic flux produced by the toroidalmagnetic cylinder 430 through the back iron material (as opposed to air)to reduce the reluctance of the magnetic circuit. In certainembodiments, therefore, the amount or thickness of the magnets formingthe toroidal magnetic cylinder (if permanent magnets are used) may bereduced when using the appropriately designed back iron circuit.

Applying Mechanical Torque or Current

In “motor” mode, current is induced in the coils 526, which will causeelectromotive forces to move the coil assembly 500 relative to thetoroidal magnetic cylinder 430 or vice versa. In “generator” mode, onthe other hand, the movement of the coil assembly 500 relative to thetoroidal magnetic cylinder 430 will cause current to be generated in theindividual coils 526 to produce a DC current as the individual coilsmove through each tunnel or radial segment 420 or 421.

In order to maintain the generated torque and/or power the individualcoils 526 in the coil assembly 500 may be selectively energized oractivated by way of a switching or controller (not shown). Theindividual coils 526 in the coil assembly 500 may be electrically,physically, and communicatively coupled to switching or controller whichselectively and operatively provides electrical current to theindividual coils in a conventional manner.

For instance, the controller may cause current to flow within anindividual coil 526 when the individual coil is within a magnetic tunnelsegment 420 with a NNNN magnetic pole configuration as illustrated inFIG. 7D. On the other hand, when the same individual coil rotates intoan adjacent magnetic tunnel segment 421 with a SSSS magnetic poleconfiguration, the controller causes the current within the individualcoil 526 to flow in a direction opposite to that when the coil was inthe NNNN magnetic pole segment 420 so that the generated magnetic forceis in the same direction as coil rotates from one adjacent magneticsegment to the other.

As discussed above, the individual coils 526 may use toroidal windingwithout end windings and in some embodiments, the individual coils maybe connected to each other in series. In other embodiments, amulti-phasic winding arrangement such as six phase, three phase, etc.winding connection may be used where the proper coils 526 are connectedtogether to form a branch of each phase. For instance, two adjacentcoils may be phase A coils, the next two adjacent coils may be phase Bcoils, and the next two adjacent coils may be phase C coils. This threephase configuration would then repeat for all individual coils 526within the coil assembly 500. In one embodiment, there are eight (8)pairs of adjacent phase A coils for a total of 16 phase A coils.Similarly, there are eight (8) pairs of adjacent phase B coils for atotal of 16 phase B coils, and there are eight (8) pairs of adjacentphase C coils for a total of 16 phase C coils. Thus, in such anembodiment, there are 48 individual coils.

When the coils are energized, the multi-phasic winding can produce arotating magnetomotive force in the air gap around the coil assembly500. The rotating magnetomotive force interacts with the magnetic fieldgenerated by the toroidal magnetic tunnel 430, which in turn producestorque on all sides of the coil assembly 500 and relative movementbetween the coil assembly and the toroidal magnetic tunnel.

In such embodiments, the individual coils 526 may be connected to abrushless motor controller (not shown) to be activated by a controlleror in a similar manner known in the art. For each phase, the motorcontroller can apply forward current, reverse current, or no current. Inoperation, the motor controller applies current to the phases in asequence that continuously imparts torque to turn the magnetic toroidaltunnel in a desired direction (relative to the coil assembly) in motormode. In certain embodiments, the motor controller can decode the rotorposition from signals from position sensors or can infer the rotorposition based on back-emf produced by each phase. In certainembodiments, two controllers may be used. In other embodiments, a singlecontroller may be used. The controller(s) controls the application ofcurrent of the proper polarity for the proper amount of time at theright time and controls the voltage/current for speed control.Regardless, the controllers allow for a switching action and a varyingvoltage action.

In other embodiments, a brushed motor/generator may be used. In suchembodiments, one or more commutators (not shown) may be used andpositioned, for instance, within the rotor hub 300 (see FIG. 1). Incertain embodiments, the number of brushes used may equal the number oftoroidal magnetic segments used in the design of the particularmotor/generator. For instance, if eight toroidal magnetic segments areused, then eight brushes may be used. The individual coils 526 in thecoil assembly 500 may be connected in series having toroidal woundwindings. In a brushed design in motor mode, a simplified reverseswitching circuit is all that is necessary to switch the currentdirection as the coils enter and exit the respective toroidal magneticsegment.

A Motor/Generator Embodiment

FIG. 9A is an exploded view of one configuration of a system 900 usingthe back iron circuit 200 and the toroidal magnetic cylinder 430 as arotor and the coil assembly 500 as a stator. FIG. 9B is an isometricview of the assembled system 900 of FIG. 9B. In FIGS. 9A and 9B, theback iron circuit 200 surrounds the toroidal magnetic cylinder 430 andthe coil assembly 500 to form the magnetic disc assembly 400 (thetoroidal magnetic cylinder 430 is not visible in FIGS. 9A and 9B). Incertain embodiments, the system 900 includes a stator side end plate 902and an extension or support ring 904 which fixedly couples the coilassembly 500 to the stator side end plate 902 (see FIG. 10).

An end of a rotor shaft 906 extends through the stator side end plate902. The rotor hub 300 couples to a rotor shaft 906 and supports theback iron circuit 200, which in turn supports the toroidal magneticcylinder 430 (not visible in FIGS. 9A and 9B). The opposing end of therotor shaft 906 is supported by the rotor side end plate 908. Whenassembled, in one embodiment, a pair of side plates 910 and 912 couplethe stator side end plate 902 to the rotor side end plate 908 asillustrated in FIG. 9B. As is known in the art, the rotor shaft 906 is amechanical load transferring device that either inputs a mechanicalrotation force into the system when in generator mode or produces amechanical rotational force when the system is in motor mode.

FIG. 10 is another exploded illustration of the system 900 where thestator or coil assembly 500 is coupled to and supported by the statorend plate 902 via the extension ring 904. Thus, the end plates 902 and908, the extension ring 904, and the coil assembly 500 (the stator) arestationary in this configuration. In contrast, the rotor hub 300 isfixedly coupled to the back iron circuit 200 which supports andpositions the toroidal magnetic cylinder 430. The rotor shaft 906 isstructurally supported by the stator end plate 902 and the rotor endplate 908. Bearing units 912 and 914 are positioned between the rotorshaft ends and the end plates to allow the rotor shaft to rotate withrespect to the end plates. Thus, as illustrated in FIG. 10, the coilassembly 500 (or stator) and toroidal magnetic disc 430 and the backiron circuit 200 (or rotor) each have their own individual end plates902 and 908, respectively—which will secure the entire arrangement ofthe machine and will ensure the integrity of the rotating components.

In certain embodiments, wires and cooling medium may enter the coilassembly 500 from the dedicated end plate 902 via the extension ring904. In contrast, the rotating components (the toroidal magnetic disc430 and the back iron circuit 200) may be coupled together and will becoupled in tandem with the rotor hub 300, which in turn is fixedlycoupled to the shaft 906.

FIG. 11 is a partial exploded view illustrating certain detailsregarding the rotor hub 300. Besides th rotor shaft 906, the rotor hub300 includes a plurality of support shoulders positioned longitudinallyalong the length of the shaft. A first bearing support shoulder 920engages and supports the bearing unit 912. A first centering shoulder922 couples to and supports the first side wall 210 of the back ironcircuit 200 (not completely shown). A center shoulder 924 engages withand supports the inner cylindrical walls 208 and 218 of the back ironcircuit 200 (see also FIG. 8). A second centering shoulder 926 supportsthe side wall 220 of the back iron circuit 200. A second bearing supportshoulder 928 is designed to engage with and support the second bearingunit 914. In certain embodiments, a keyway 930 may be defined in eitherend (or both ends) of the rotor shaft 906.

In the embodiment illustrated in FIGS. 9A-11, the coil assembly 500 isthe stator. In other configurations, the coil assembly 500 may be arotor. Furthermore, the embodiments as illustrated is only one way ofconfiguring and supporting the coil assembly 500. In other embodimentsthe coil assembly 500 may be supported by support ring extending througha center slot between the outer cylindrical walls 206 and 216 from thecoil assembly to an exterior casing or housing. In yet other embodimentswhen the coil assembly 500 is functioning as a rotor, the coil assemblymay be supported by a support ring extending through a center slotbetween the inner cylindrical walls 208 and 218 from the coil assemblyto the a shaft. The exact configuration depends on design choices as towhether the coil assembly is to be the stator or the rotor.

Advantages of Certain Embodiments

In sum, certain disclosed embodiments have several advantages whencompared to traditional motors and generators. Surrounding the coilswith magnets as described above creates more flux density and the forcesare now all in the direction of motion which may create more torque,minimize vibration, and minimize noise—as compared to conventionalmotors where forces may try to pull the coil downwards or push itupwards (depending on the polarity), not in the direction of motion. Asdiscussed above, most of the magnetic fields generated are in thedirection of motion so there is little, if any, wasted field structure.Continuous torque and continuous power, therefore, are greatlyincreased. Furthermore, continuous torque density, continuous powerdensity by volume, and continuous power density by weight are alsoincreased when compared to conventional electric motors.

In certain embodiments, the equivalent full torque is available at startwith no locked rotor current losses. The permanent magnet configurationhas reduced inrush current at start.

In certain embodiments, the coil assembly may be compact and yet thecoils are easily cooled because they are surrounded by an effective heatsink. Because there is no reason to overlap the coil windings, there islittle, if any unwanted field induction—which also contributes to a moreefficient design. One of the advantages of this configuration overconventional motors is that the end turns (in this case the radialsection of the coils) are part of the “active section” of the invention.In conventional motors, the axial length of the copper conductor is thesection that produces power. The end turns are a penalty, adding weightand losses, but not producing power because the end region fields arenot effectively linking the end windings. However, in the abovedisclosed embodiments, the entire coil winding is effectively used toproduce torque due to the side wall or axial magnets which are axiallymagnetized—efficiently utilizing the copper windings.

In the “DC” configuration, the motor may run independent of power linefrequency or manufactured frequencies reducing the need for expensivepulse width modulated drive controllers or similar controllers.

The foregoing description of the embodiments of the invention has beenpresented for the purposes of illustration and description. It is notintended to be exhaustive or to limit the invention to the precise formdisclosed. Many combinations, modifications and variations are possiblein light of the above teaching. For instance, in certain embodiments,each of the above described components and features may be individuallyor sequentially combined with other wall portion, components or featuresand still be within the scope of the present invention, for instance:

In one embodiment, there may be a method of producing a current, themethod characterized by: forming an area of magnetic concentrationwithin a first radial segment defined in section by an outer magneticcylinder wall portion having a first longitudinal length, an innermagnetic cylinder wall, a first magnetic side wall portion having afirst radial length, and a second magnetic side wall portion having asecond radial length, each wall portion having their like magnetic polesfacing an interior of the first radial segment and the firstlongitudinal length is greater than either the first radial length orthe second radial length, forming a second area of magneticconcentration within a second radial segment defined by an second outermagnetic cylinder wall portion having a first longitudinal length, asecond inner magnetic cylinder wall portion, a third magnetic side wallportion having a first radial length, and a fourth magnetic side wallportion having a second radial length, each wall portion having theirlike magnetic poles facing away from an interior of second radialsegment, positioning a coil within a slot formed by adjacent teeth of acoil assembly, rotating a shaft coupled to the coil assembly, rotatingthe coil through the first segment and extracting current in a firstdirection from the coil, rotating the coil through the second segmentand extracting current in a second direction from the coil.

A method of producing a current, the method characterized by: forming anarea of magnetic concentration within a first radial segment defined byan outer magnetic cylinder wall portion having a first longitudinallength, an inner magnetic cylinder wall, a first magnetic side wallportion having a first radial length, and a second magnetic side wallportion having a second radial length, each wall portion having theirlike magnetic poles facing an interior of the first radial segment andthe first longitudinal length is greater than either the first radiallength or the second radial length, forming a second area of magneticconcentration within a second interior cavity defined by an second outermagnetic cylinder wall portion having a first longitudinal length, asecond inner magnetic cylinder wall portion, a third magnetic side wallportion having a first radial length, and a fourth magnetic side wallportion having a second radial length, each wall portion having theirlike magnetic poles facing away from an interior of the second radialsegment, positioning a coil within a slot formed by adjacent teeth of acoil assembly, rotating a shaft coupled to the first radial segment andthe second radial segment such that the first radial segment is rotatedabout the coil and current of a first direction is extracted from thecoil, the second radial segment is rotated about the coil and current ofa second direction is extracted from the coil.

Additionally, undescribed embodiments which have interchanged componentsare still within the scope of the present invention. It is intended thatthe scope of the invention be limited not by this detailed description,but rather by the claims or future claims supported by the disclosure.

The abstract of the disclosure is provided for the sole reason ofcomplying with the rules requiring an abstract, which will allow asearcher to quickly ascertain the subject matter of the technicaldisclosure of any patent issued from this disclosure. It is submittedwith the understanding that it will not be used to interpret or limitthe scope or meaning of the claims.

Any advantages and benefits described may not apply to all embodimentsof the invention. When the word “means” is recited in a claim element,Applicant intends for the claim element to fall under 35 USC 112(f).Often a label of one or more words precedes the word “means”. The wordor words preceding the word “means” is a label intended to easereferencing of claims elements and is not intended to convey astructural limitation. Such means-plus-function claims are intended tocover not only the structures described herein for performing thefunction and their structural equivalents, but also equivalentstructures. For example, although a nail and a screw have differentstructures, they are equivalent structures since they both perform thefunction of fastening. Claims that do not use the word “means” are notintended to fall under 35 USC 112(f).

1. An electric motor/generator comprising: a magnetic toroidal cylinderpositioned about a longitudinal axis, the magnetic toroidal cylindercomprising at least: a first tunnel segment comprising: an outermagnetic cylinder wall portion having a longitudinal length, an innermagnetic cylinder wall portion, a first magnetic side wall portionhaving a first radial length, a second magnetic side wall portion havinga second radial length, wherein the outer magnetic cylinder wallportion, the inner magnetic cylinder wall portion, the first magneticside wall portion, and the second magnetic side wall portion arepositioned to form an interior cavity and have their like magnetic polesfacing the interior cavity, wherein the longitudinal length of the outermagnetic cylinder wall portion is greater than the first radial lengthof the first magnetic wall portion or the second radial length of thesecond side wall portion, an adjacent tunnel segment comprising: asecond outer magnetic cylinder wall portion having a second longitudinallength, a second inner magnetic cylinder wall portion, a third magneticside wall portion having a third radial length, a fourth magnetic sidewall portion having a fourth radial length, wherein the second outermagnetic cylinder wall portion, the second inner magnetic cylinder wallportion, the third magnetic side wall portion, and the fourth magneticside wall portion form a second interior cavity have their like magneticpoles facing away from the second interior cavity and, wherein thelongitudinal length of the second outer magnetic cylinder wall portion102 is greater than the third radial length of the third magnetic wallportion or the fourth radial length of the fourth side wall portion, acoil assembly positioned about the longitudinal axis and within themagnetic toroidal cylinder, the coil assembly including a core at leastpartially positioned within the first interior cavity and the secondinterior cavity, a plurality of radial teeth extending longitudinallyand radially from the core to form a plurality of slots between theradial teeth, a plurality of coils positioned within the slots, and themagnetic toroidal cylinder is adapted to rotate relative to the coilassembly.
 2. The electric motor/generator of claim 1 wherein each toothin the plurality of radial teeth has an outer pair of fins and an innerpair of fins extending in a tangential direction.
 3. The electricmotor/generator of claim 2 wherein each tooth in the plurality of teethhas a first pair of radial fins connecting the outer and inner pair offins together and an opposing pair of radial fins connecting the outerand inner pair of fins together.
 4. The electric motor/generator ofclaim 1 wherein the coil assembly is formed from the group of materialsconsisting of a soft magnetic material, hard magnetic material, acomposite material, an ferrous alloy, or a laminated material.
 5. Theelectric motor/generator of claim 1, wherein adjacent coils areconnecting together to form a branch of a multi-phase winding pattern.6. The electric motor/generator of claim 1, wherein the coil assemblyhas a plurality of internal chambers with electric conductors positionedtherein.
 7. The electric motor/generator of claim 1, wherein the coilassembly has a plurality of internal chambers to allow for cooling ofthe coils.
 8. The electric motor/generator of claim 1, where themagnetic toroidal cylinder comprises eight tunnel segments includingfour tunnel segments with NNNN magnetic configuration interspersed amongfour tunnel segments with SSSS magnetic configuration.
 9. The electricmotor/generator of claim 8, further comprising a controller adapted tocause a first current direction to flow within an individual coil whenwithin a tunnel segment with the NNNN magnetic configuration and causinga second current of the opposite direction to be generated when theindividual coil when within a tunnel segment with the SSSS magneticconfiguration.
 10. The electric motor/generator of claim 1, where themagnetic toroidal cylinder defines at least one generally circular slotand includes magnets positioned proximal to the circular slot such thata cross magnetic field is established across the circular slot.
 11. Theelectric motor/generator of claim 10, wherein the circular slot isdefined within or adjacent to the first side wall portion.
 12. Theelectric motor/generator of claim 1, further comprising an extensionring fixedly coupled to the coil assembly and a side plate fixedlycoupled to the extension ring where the extension ring and side plateincludes passages for electrical conductors and cooling medium.
 13. Theelectric motor/generator of claim 1, further comprising a back ironcircuit fixedly coupled to magnetic toroidal cylinder and a rotor hubfixedly coupled to the back iron circuit.
 14. A method of producingmechanical rotation, the method characterized by: forming an area ofmagnetic concentration within a first interior cavity defined in sectionby an outer magnetic cylinder wall portion having a first longitudinallength, an inner magnetic cylinder wall portion, a first magnetic sidewall portion having a first radial length, and a second magnetic sidewall portion having a second radial length, each wall portion havingtheir like magnetic poles facing the first interior cavity and the firstlongitudinal length is greater than either the first radial length orthe second radial length, forming a second area of magneticconcentration within a second interior cavity defined in section by ansecond outer magnetic cylinder wall portion having a first longitudinallength, a second inner magnetic cylinder wall portion, a third magneticside wall portion having a first radial length, and a fourth magneticside wall portion having a second radial length, each wall portionhaving their like magnetic poles facing away from the second interiorcavity and the first longitudinal length of the second outer magneticcylinder wall portion is greater than either the first radial length ofthe third magnetic side wall portion or the second radial length of thefourth magnetic side wall portion, positioning a coil within the firstinterior cavity, applying a current in a first direction to the coil tocause the coil to move to the second interior cavity, applying a currentin a second direction to the coil when the coil is within the secondinterior cavity to move the coil out of the second interior cavity, andcoupling a longitudinal shaft to the coil such that as the coil rotatesfrom the first interior cavity to the second interior cavity, thelongitudinal shaft rotates.
 15. A method of producing mechanicalrotation, the method characterized by: forming an area of magneticconcentration within a first interior cavity defined in section by anouter magnetic cylinder wall portion having a first longitudinal length,an inner magnetic cylinder wall portion, a first magnetic side wallportion having a first radial length, and a second magnetic side wallportion having a second radial length, each wall portion having theirlike magnetic poles facing the first interior cavity and the firstlongitudinal length is greater than either the first radial length orthe second radial length, forming a second area of magneticconcentration within a second interior cavity defined in section by ansecond outer magnetic cylinder wall portion having a first longitudinallength, a second inner magnetic cylinder wall portion, a third magneticside wall portion having a first radial length, and a fourth magneticside wall portion having a second radial length, each wall portionhaving their like magnetic poles facing away from the second interiorcavity and the first longitudinal length of the second outer magneticcylinder wall portion is greater than either the first radial length ofthe third magnetic side wall portion or the second radial length of thefourth magnetic side wall portion, positioning the first interior cavityabout a first coil, applying a current in a first direction to the firstcoil to cause the first interior cavity to move relative to the firstcoil, positioning the second interior cavity about the first coil,applying a current in a second direction to the first coil when thefirst coil is within the second interior cavity to cause the secondinterior cavity to move relative to the first coil, coupling alongitudinal shaft to the walls forming the first and second interiorcavities such that as the first and second cavities rotate, thelongitudinal shaft rotates.